SECTION 15172 - Yaskawa



SECTION 15172VARIABLE FREQUENCY DRIVESPART 1. GENERAL1.01SECTION INCLUDESVariable Frequency Drive (VFD)1.02RELATED SECTIONSSection 16195 - Electrical Identification: Engraved nameplates1.03REFERENCESNEMA ICS 3.1 - Safety Standards for Construction and Guide for Selection, Installation and Operation of Variable Frequency Drive SystemsNEMA 250 - Enclosures for Electrical Equipment (1000 Volts Maximum)UL and cUL approvedIEEE Standard 519UL 508C (Power Conversion)UL 508A (Industrial Control Panel)CSA 22.2 No. 14-95 (Industrial Control Equipment)EN 61800-5-1 (LVD)EN 61800-3 First Environment RestrictedCE mark 2006/95/EC LVDCE mark 2004/108/ECRoHSIBC 2006 Seismic – referencing ASC 7-05 and ICC AC-1561.04SUBMITTALSSubmit under provisions of Section 01340.Shop Drawings shall include: Wiring diagrams, electrical schematics, front and side views of enclosures, overall dimensions, conduit entrance locations and requirements, nameplate legends, physical layout and enclosure details.Product Data: Provide data sheets showing; voltage, ratings of customer use switching and over-current protective devices, short circuit ratings, and weights.Manufacturer's Installation Instructions and Technical Manuals: Indicate application conditions and limitations of use stipulated by product testing agency specified under regulatory requirements. Include instructions for storage, handling, protection, examination, preparation, installation, and starting of adjustable speed drive. Document the sequence of operation, cautions and warnings, troubleshooting procedures, spare parts lists and programming guidance.1.05QUALITY ASSURANCEVFD shall have a minimum design life of 10 years.1.06OPERATION AND MAINTENANCE DATASubmit under provisions of Section 01700.Include instructions for starting and operating VFD, and describe operating limits, which may result in hazardous or unsafe conditions.1.07QUALIFICATIONSManufacturer must have a minimum of 50 years of documented experience, specializing in variable frequency drives.1.08DELIVERY, STORAGE, AND HANDLINGDeliver, store, protect and handle products to site, under provisions of Section 01610.Accept VFD on site in original packing. Inspect for damage.Store in a clean, dry space. Maintain factory wrapping, or provide an additional heavy canvas or heavy plastic cover, to protect units from dirt, water, construction debris, and traffic.Handle carefully, in accordance with manufacturer's written instructions, to avoid damage to components, enclosure, and finish.1.09WARRANTYProvide VFD warranty, for one year from date of startup, not to exceed 18 months from date of shipment. Warranty shall include parts, and labor allowance for repair hours.PART 2. PRODUCTS2.01MANUFACTURERSVFD shall be GA800 type, manufactured by Yaskawa America Inc.Motors should be inverter duty rated, per NEMA MG1 part 31, for motor-drive compatibility.2.02DESCRIPTIONProvide enclosed variable frequency drives suitable for operation at the current, voltage, and horsepower indicated on the schedule. Conform to requirements of NEMA ICS 3.1.2.03RATINGSVFD must have the minimum range of horsepower ratings: 1 to 150 HP at 240 VAC; 1 to 600 HP at 480 VACVFD must have Heavy Duty and Normal Duty ratings and software switch to optimize the VFD size to the application.VFD shall have a built-in Dynamic Braking Transistor through a minimum of 125HP normal duty (100HP heavy duty) at 480V, and through a minimum of 60HP normal duty (50HP heavy duty) at 240VAn alternate version of 480V VFD, from 75 to 600HP, with an integrated 12 pulse rectifierVFD must operate, without fault or failure, when voltage varies plus 10% or minus 15% from rating, and frequency varies plus or minus 5% from rating.VFD shall be __________ volts, _______ Hz, 3 Phase.Displacement Power Factor: 0.98 over entire range of operating speed and load.Service factor: 1.0Operating Ambient Temperature:Open Chassis: -10C to 50C (14F to 122F), with derating for up to 60C (140F)UL Type 1: -10C to 40C (14F to 104F)Ambient storage temperature: -20C to 60C (-4F to 140F).Humidity: 0% to 95%, non-condensing.Altitude: Up to 3,300 feet (1000m), higher altitudes achieved by derating.Vibration: 9.81m/s2 (1 G) from10 to 20 Hz; 2.0 m/s2 (0.2 G) from 20 Hz to 55 Hz.Minimum Efficiency: 97% at full load.Starting Torque: 200% starting torque shall be available from 0.3 Hz to 60 Hz.Overload capability: 150% of rated current for 60 seconds for Heavy Duty applications; 110% of rated current for 60 seconds for Normal Duty applicationsControlled speed range (induction motor): – Open Loop – 200:1 or greater – Closed Loop – 1500:1 or greater.Total Harmonic Distortion (THD) compliance: Given the information provided by the customer’s electric power single line diagram and distribution transformer data, the VFD manufacturer shall carry out an analysis of the system. The analysis reviews the potential for the proposed equipment, and any existing equipment, to meet IEEE 519 (tables 10.2 and 10.3) recommendations at the Point of Common Coupling (PCC). The result of the analysis shall determine if additional power quality improvement measures should be included in the proposal to meet the THD recommendations of IEEE 519. The PCC shall be at the primary side of the main distribution transformer.VFDs must be suitable for use on a circuit capable of delivering not more than 100,000 RMS symmetrical amperes.2.04DESIGNVFD shall employ microprocessor based inverter logic, isolated from all power circuits.VFD shall include surface mount technology with protective coating, able to meet IEC 60721-3-3, levels 3C2 and 3S3.VFD shall be able to be mounted with the heatsink out the back of the enclosure. A certified solution shall be available to achieve UL Type 12 on the backside.VFD shall employ a PWM (Pulse Width Modulated) power electronic system, consisting of: Input Section: VFD input power stage shall convert three-phase AC line power into a fixed DC voltage via a solid-state full wave diode rectifier, with MOV (Metal Oxide Varistor) surge protection.A minimum of 3% DC bus impedance to minimize reflected current (40 HP and larger). Intermediate Section:DC bus as a supply to the VFD output Section shall maintain a fixed voltage with filtering and short circuit protection.DC bus shall be interfaced with the VFD diagnostic logic circuit, for continuous monitoring and protection of the power components. Output Section Insulated Gate Bipolar Transistors (IGBTs) shall convert DC bus voltage to variable frequency and voltage.The VFD shall employ PWM sine coded output technology to power the motor.VFD shall have selectable control methods to control induction, interior permanent magnet (IPM), surface permanent magnet (SPM), and synchronous reluctance motors. VFD shall be able to control the motor with (closed loop) and without (open loop) a feedback device (encoder, resolver, etc.).Auto-tuning capability for all motors for easy commissioning.VFD shall be able to switch from speed control to torque control on the fly via a digital input or network communication.VFD shall be able to produce 100% continuous torque at zero speed when running in a closed loop control mode.VFD shall offer a low noise, low carrier frequency function.VFD should be able to be mounted next to each other with zero clearance for ratings up to 30HP Normal Duty (25HP Heavy Duty).VFD shall have embedded Modbus RTU accessible via a RS485 communication port. The termination resistor shall be embedded and selectable (enabled/disabled).VFD shall include three independent multi-function analog inputs, individually selectable for unipolar voltage, bipolar voltage, or current. One of the inputs shall also be selectable for PTC. Each input shall have a programmable bias and gain. The inputs shall be individually programmed for, but not limited to:Speed ReferencePID SetpointPID FeedbackMotor TemperatureTorque LimitVFD shall include eight independent multi-function digital input terminals that can be set for sinking/sourcing and internal/external power supplies, with a scan time of 0.5ms or faster, programmable for single or multiple scan. The inputs shall be individually programmed for, but not limited to:16 Multi-step Speed References plus JogDrive EnableSpeed/Torque ChangeoverFault ResetFast StopVFD shall include a multi-function 32 kHz pulse train input that shall be programmed for, but not limited to:Frequency ReferencePID SetpointPID FeedbackSpeed Feedback (V/f mode only)VFD shall include two independent analog outputs, selectable for unipolar voltage, bipolar voltage, or current. The outputs shall be individually programmed for, but not limited to:Output FrequencyOutput CurrentMotor SpeedOutput PowerOutput TorqueVFD shall include one fixed form "C" Fault contact and three programmable multi-function form "A" contacts. These output relay contacts shall all be rated for 1A at 250 VAC and shall be programmed for, but not limited to:Speed AgreeZero SpeedDrive ReadyDuring RunDuring ReverseVFD shall include a multi-function 32 kHz pulse train output that shall be programmed for, but not limited to:Output FrequencyMotor SpeedPID SetpointPID FeedbackVFD shall include auxiliary power input for the purpose of powering control circuit while main power is removed. When powered by 24Vdc, all control circuits including I/O, expansion cards, and keypad shall be completely functionalVFD shall include 150mA of 24Vdc power for customer use. This capacity shall be in addition to power required to operate the VFD’s digital inputs.VFD shall include a control power loss ride through capable of 2 seconds or greater.VFD shall have a fault trace function to capture relevant monitor values at the time of the most recent fault.VFD shall include a battery powered real time clock and history of the most recent 10 fault with associated time stamps based on the real time clock.VFD shall include memory card slot, capable of accepting up to 32GB memory for capturing high speed drive data with programmable sample rate. Drive data on memory card shall be accessible via stand card reader and displayable in VFD supplier’s free graphical computer program.VFD shall have preventative maintenance monitors for predicting the remaining life of IGBTs, cooling fans, bus capacitors and pre-charge relays.VFD shall have the following minimum protective functions: Overheat, motor overload, VFD overload, short circuit, overvoltage, undervoltage, input phase loss, output phase loss, output ground fault and overcurrent.VFD shall have a USB-OTG port for easy connection to a computer or mobile device (tablet or smartphone). VFD shall not require any other power source (other than what is provided from the USB connection) to gain read/write access to all VFD settings, and to flash VFD firmware. Neither main input power nor auxiliary control input power shall be necessary.VFD supplier shall provide free PC and Mobile software that includes online and offline parameter management, application wizards, oscilloscope function, network configurator for Ethernet, parameter conversion tool and diagnostic functions.VFD supplier shall provide free cloud storage with secure access, for the purpose of storing drive settings and other data associated with each application.VFD shall have a removable keypad for programming, operating, and monitoring. Keypad shall have an LCD display with backlight and contrast adjustment, and shall be viewable in direct sunlight. Keypad shall have memory to backup all drive setting. Keypad shall be capable of 32 character descriptions and support at least the following languages: English, French, Spanish, Portuguese, German, Italian, Greek, Polish, Czech, Turkish, Russian, Japanese, and Chinese.VFD shall provide plain language readouts of output frequency in hertz, PID feedback in percent, output voltage in volts, output current in amps, output power in kilowatts, DC bus voltage in volts, interface terminal status, heatsink temperature and fault conditions.VFD shall have an independent PID loop that can be used to vary the VFD output to maintain a set point of an independent process.VFD shall include loss of input signal protection, with a selectable responses including running at a preset speed. VFD shall include electronic thermal overload protection for both the drive and motor. The electronic thermal motor overload shall be approved by UL.VFD shall include an embedded category 3 Safe Torque Off (STO) solution, TUV certified to EN/ISO 13849-1 (PLe) and IEC 62061 (SIL3).VFD shall have pluggable control wire terminals (or pluggable terminal board) that allow drive replacement without removing and re-installing individual wires from the digital input and analog control terminals.VFD shall use 24 VDC cooling fans for all ratings. Fans shall be mounted at the top of the drive for easier access.VFD shall include an embedded programmable function blocks with both logic an analog math functions. Functions blocks shall be capable of connecting to internal drive functions and to both standard and expansion I/O.VFD shall include the following program functions:Capability to reset all parameters back to the factory settings. Capability to reset all parameters back to a user-defined set of parametersCapability to see only the parameters that have been modified Ability to set the motor speed in Hertz, RPM, percent or custom units.Critical frequency rejection capability: 3 selectable, adjustable dead bands.Auto restart capability: 0 to 10 attempts with adjustable delay between attempts.Ability to close fault contact after the completion of all fault restart attempts.Kinetic energy braking function for deceleration upon power loss.Overvoltage suppression function for cyclic regenerative loads.Stall prevention capability."S" curve soft start / soft stop capability with four programmable corners.Four sets of acceleration/deceleration times, selectable via digital input.Acceleration/deceleration adjustment from 0.00 to 6000 seconds.Bi-directional Speed search capability, in order to start a rotating load.Multiple preset and 1 custom volts per hertz pattern.Programmable security code to prevent parameter setting changes.Heatsink over temperature speed fold back capabilityTerminal status indication.Motor thermistor input.Reverse direction lockout.Torque limit adjustment from 0% to 300% of rated torque of the motor.Input signal or serial communication loss detection and selectable response.Automatic energy saving function.Undertorque/Overtorque Detection.Overexcitation braking function to quickly stop the motor.Cooling fan failure detection and selectable drive action.Seventeen preset speeds.Ability to remove digital operator during VFD operation.PRODUCT OPTIONSVFD shall have the following optional accessories:Fieldbus Adapters: DeviceNet, Profibus DPEthernet Media Adapters (single and multiport): EtherNet/IP, Modbus TCP/IP, ProfiNet, and EtherCAT.Expansion I/O for both analog and digital115V digital input converterIncremental Encoder InterfaceAbsolute Encoder Interface (Heidenhain Endat 2.2 and Stegmann Hiperface)Resolver InterfaceBluetooth KeypadUL Type 1 KitRemote Keypad Mounting Kit: rated UL Types 1, 12, 3R, and 4X.2.06SOURCE QUALITY CONTROLInspect and test, under load, each completed VFD at the completion of production using a computerized, automated testing fixture. All test results shall be stored as detailed quality assurance data.PART 3. EXECUTION3.01EXAMINATIONVerify that surface is suitable for VFD installation.Do not install VFD until the installation environment can be maintained, within the service conditions required by the manufacturer.3.02INSTALLATIONInstall VFD where indicated, in accordance with manufacturer's written instructions and NEMA ICS 3.Tighten accessible connections and mechanical fasteners after placing VFD.3.03FIELD QUALITY CONTROLField inspection and testing to be performed under provisions of Section 01400.Inspect completed installation for physical damage, proper alignment, anchorage and grounding.3.04MANUFACTURER'S FIELD SERVICESPrepare and start systems under provisions of Section 01400.3.05ADJUSTINGCarry out adjusting work under provisions of Section 01700. Make final adjustments to installed VFD, to assure proper operation of the system. ................
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